cooling SSANGYONG MUSSO 2003 Owners Manual
[x] Cancel search | Manufacturer: SSANGYONG, Model Year: 2003, Model line: MUSSO, Model: SSANGYONG MUSSO 2003Pages: 1574, PDF Size: 26.41 MB
Page 938 of 1574
AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary checks. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded. Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below. Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours before adding transmission fluid (this will allow the transmission to be within the correct temperaturerange).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park. Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.
Page 1157 of 1574
SECTION 7D
FULL AUTOMATIC TEMPERATURECONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7D-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7D-1
Service Specifications . . . . . . . . . . . . . . . . . . . 7D-3
Schematic and Routing Diagrams . . . . . . . . 7D-4
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 7D-4
FATC Block Diagram . . . . . . . . . . . . . . . . . . . . 7D-5
Component Locator . . . . . . . . . . . . . . . . . . . 7D-6 TABLE OF CONTENTS
Ventilation System . . . . . . . . . . . . . . . . . . . . . . 7D-6
Function Description . . . . . . . . . . . . . . . . . . . . 7D-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Maintenance and Repair . . . . . . . . . . . . . . 7D-11 FATC Control Panel . . . . . . . . . . . . . . . . . . . 7D-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7D-15
FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects incar temperature, ambient temperature, sun load and coolant temperature and controls airconditioner system
blowing capacity, outlet temperature and intaking/outlet mode to maintain interior comfort.
SPECIFICATIONSSPECIFICATIONS
Application
Core Size (LxWxT)
Core Type
Expansion Valve Type Thermostat
Resister TypeCooling Capacity Description
237.0x232.0x92.0 Aluminum plate
Angle
ON:4.5±0.6 °C, OFF:1.5±0.6 °C
Aluminum plate
4,500 Kcal/h(AT 420 CMH)
Evaporator Unit
Application
Capacity
Type Description
650-750 g R134a
Refrigerant
Page 1366 of 1574
4-2 USAGE AND CAPACITY OF FUSES IN FUSE BOX
60A 80A 80A30A30A40A40A60A60A10A10A15A15A15A15A10A10A30A
Ef1Ef2Ef3Ef4Ef5Ef6Ef7Ef8Ef9
Ef10Ef11Ef12Ef13Ef14Ef15Ef16Ef17Ef18
1. ENGINE ROOM FUSE & RELAY BOX
1) ENGINE ROOM FUSE BLOCK
2) USAGE OF FUSE IN ENGINE ROOM FUSE BOX
* 30 : Battery(+) Power Supply
Front
fog
Lamp
Head
Lamp
(LOW)
Head
Lamp (HI)
Illumination
Relay
Horn
Relay
A/CON C101
C102 C103 S101
Cooling fan-2
Cooling fan-1
Ef10 10ATAIL LAMP LH
Ef11 10ATAIL LAMP RH
Ef12 15AHEAD LAMP LH
Ef13 15AHEAD LAMP RH
Ef14 15AFRT FOG LAMP
Ef15 15ADOOR LOCK
Ef16 10AHORN
Ef17 10AA/CON COMP
Ef18 30ABLOWER
DSL GSL
COMP RESIS
TOR
109876 5432121 20 19 18 17 16 15 14 13 12 11
21
123
12
Ef9 60A
BATT1
Ef8 60ABATT2
Ef7 40AIGNITION SWITCH
Ef6 40A
FUSIBLE LINK
HEADLAMP
Ef5 30ACOOLING FAN
Ef4 30APOWER
WINDOW
2) FUSIBLE LINK FUSE BOX
80A 80A 60A
E
f3Ef2Ef1
3) RELAY TERMINAL NUMBER
8687
8530
S
BL8587a
30
87
86
4PIN RELAY 3PIN RELAY 5PIN RELAY ABS & ABD
Generator
Preheating
Power Window
Cooling FanHead Lamp
Ignition Switch Battery 2 Battery 1
Tail Lamp LH
Tail Lamp RH
Head Lamp LH
Head Lamp RH
Front Fog Lamp Door LockHorn
A/C Compressor
Blower
Fuse No Capacity UsagePower Supply
30 BAT(+)
Illumination(58)
30 BAT(+)
Page 1368 of 1574
4-4 USAGE AND CAPACITY OF FUSES IN FUSE BOXSDM Chime BellImmobilizer UnitSticsRekesEBCM
4 Pin 4 Pin 4 Pin4 Pin4 Pin4 Pin4 Pin 4 Pin 3 Pin3 Pin
82330-05000 84190-05100 84150-0130084150-0130084150-0130084150-0130084150-01300 84150-01300 84130-0500084130-05000
Part Name Part Number
Remarks
Resistor W/Diode (GSL) A/C Compressor Relaly (DSL)A/C RelayCooling Fan - 1 RelayCooling Fan - 2 RelayFront Fog Lamp Relay Head Lamp Relay (Low) Head Lamp Relay (Hi)Illumination RelayHorn Relay
3. POSITION OF RELAY, CONTROL UNIT AND PARTS NUMBER
1) ENGINE ROOM FUSE BLOCK
2) RELAY BOX ABOVE I.P FUSE BLOCK
5 Pin 5 Pin 3 Pin5 Pin5 Pin4 Pin4 Pin 4 Pin 4 Pin 4 Pin 4 Pin 4 Pin
84210-05001 84210-05001 84410-05100
66182253386618225338
84150-0130084150-01300 84150-01300 84150-01300 84150-0130084150-0130084190-05100
Part Name Part Number Remarks
Front Wiper Relay Defogger RelayTurn Signal Lamp RelayFuel Pump Relay (GSL)Cigar Lighter, P/socket Relay (DSL)A/T Shift lock Relay PNP Relay Sun Roof RelayA/T "B" Switch Interlock Relay Power Window Relay ECL RelayABS Warning Lamp Relay
3) CONTROL UNIT
Below The Audio
Beside The SDM
Behind the Wiper Switch Upper The Accelerator Upper The Stics
I/P Center Console Floor Panel
8690005800 8661005000869500580087110058008716105000
4891005000X
Part Name Part Number Remarks
Page 1372 of 1574
17. COOLING FAN, A/C COMPRESSURE CIRCUIT................................................................... 5-102
1) GASOLINE-HFM ................................................................................................................. .................................. 5-102
2) GASOLINE-MSE ..................................................................................................................................................... 5-104
3) DIESEL ................................................................................................................................................................... 5-106
18. MANUAL AIR CONDITIONER CIRCUIT ................................................................................. 5-108
1) BLOWER MOTOR CIRCUIT ............................................................................................................................... 5-108
2) INTAKE MOTOR, MODE MOTOR CIRCUIT ............................................................................................. ........ 5-110
19. SATC(SEMI AUTO TEMPERATURE CONTROL) CIRCUIT .................................................. 5-112 1) BLOWER MOTOR CIRCUIT ............................................................................................................................... 5-112
2) SENSOR(AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT ...................................................... 5-114
3) INTAKE MOTOR, MODE MOTOR CIRCUIT ............................................................................................. ........ 5-116
20. FATC (FULL AUTO TEMPERATURE CONTROL) CIRCUIT ................................................ 5-118 1) BLOWER MOTOR, MODE MOTOR, INTAKE MOTOR CIRCUIT.................................................................... 5-118
2) SENSOR(AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT ...................................................... 5-120
21. HEAD LAMP CIRCUIT ........................................................................................................... .. 5-122
22. HEAD LAMP LEVEL'G DEVICE CIRCUIT .............................................................................. 5-124
23. ILLUMINATION CIRCUIT ........................................................................................................ .. 5-126
24. POSITION LAMP, TAIL LAMP, LICENCE PLATE LAMP CIRCUIT ....................................... 5-128
25. HAZARD LAMP CIRCUIT ........................................................................................................ 5-130
26. BACK UP LAMP CIRCUIT ...................................................................................................... 5 -132
27. FRT FOG LAMP CIRCUIT ....................................................................................................... 5-134
28. REAR FOG LAMP CIRCUIT .................................................................................................... 5- 136
29. SHIFT LOCK SOLENOID, STOP LAMP CIRCUIT ................................................................. 5-138
1) M/T, MB A/T, DSL BTRE A/T .................................................................................................... .......................... 5-138
Page 1407 of 1574
5-40 ELECTRICAL WIRING DIAGRAMS
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFTACTUATOR, RESONANCE FLAP CIRCUIT
Main - Engine Engine - Main Engine Main - ECM Main Engine Main - ECM MainMain - ECM Main
C101 (21Pin, Colorless)C109 (16Pin, Black) C111 (40Pin, Black) C112 (6Pin, Gray) C213 (6Pin, Colorless)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C101
W/H MAIN C109
W/H ENGINE
CAM SHAFTACTUATOR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Center The Engine Room Dash PanelCenter The Engine Room Dash Panel Beside Yhe ECM (MSE)
12345 678910
11 12 13 14 15 16 17 18 19 20 21
12
CMP
SENSOR
123
HFM SENSOR
12 345
C213
W/H ECM MAIN C112
W/H ENG. MAIN
321
654
321
654
CKP SENSOR
12
OVPR
2167
5348
C111
W/H ECM MAIN
10 1
20 11
30 21
40 31
RESONANCE
FLAP
12
ECMSIG
SIG
SIG
SIG
SIG 5V
#5
#2
#1
12 #4
#3
#2
12
71
73 97 104 106 80 105 108 81 100 99 72 70 27#6
A/C
Relay "85"
35
Cooling Fan
Motor Relay "86"
44
Thermo
Amp"1"
45
EBCM
(ABD) "32"
"F1"2
Cluster
(ABD
Warning Lamp) "4"
#1
#3
12
OVPR
"8"
C112 3
12
C101
8
C213
BW PR
PR BG B BG BW
BW
BW
BY
LB BYLW
BY
BG BY
BB WBYI
gnition
Coil
1
C112 6
C109
16
C112 4
C213 YG
RG BrGr BrG GBr RL YW Br RL BrY YG G GW GGW
YW Br BrY YG
RG GV
RG BrG GBr
GV
YG RL 1
2
3
OVPR "2" Cam Shaft
Actuator CMP Sensor HFMS CKPAIR
TEMP SIG
( - ) SIG
( + )
B+ Ref
13
21
-+2
2
1
132 5 4
Resonance Flap C111
27 25
24 29 15 28 30 16 26
11
Page 1468 of 1574
5-102 ELECTRICAL WIRING DIAGRAMS
17. COOLING FAN, A/C COMPRESSURE CIRCUIT
1) GASOLINE - HFM
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Engine Engine - Main Main - Air Con MainMain Engine
C101 (21Pin, Colorless) C103 (21Pin, White)C109 (16Pin, Black) C212 (17Pin, White) S204 (Black) G101 G103
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Behind The Glove BoxUpper Right The Audio Behind The Left Lamp Behind The Right Head Lamp
COOLING
RESISTER
12
C109
W/H ENGINEC212
W/H MAIN
12345 678910
11 12 13 14 15 16 17
COOLING FAN (LH)
12
12121234
A1 A9 A8A16
B1B11 B20
B10
1234 567
8 9 10 11 12 13 14 15 16
12
COOLING
FAN (RH) THERMO#1
SWITCH THERMO#2
SWITCH THERMO
AMP FATC
A/C CONTROL PANEL
Cooling FanRelay #2
Cooling Fan Relay #130 86
87
BG BG
85
Ef5
30A
G103 G101B
B
LB
L
L LW
LWLW
LW
L R
M
1
1
2 R
R
R B
L
L
LY Y
B B
Cooling
Fa nLH
30 86
87 85 1
5
S204
F19
10A
A/C
Relay30
86
87
85
Cooling Fan
Motor Relay30
86
87 85
11
C101
1
C103
Ef8
60A
Ef17
10A
C1013 C101
8
C212
11 C109
7
A16
FAT C
SATC/ MTC
A/C Switch A/C Switch G
LW
BW BW
BG
BrR
BrR BY
A/C Compressor
2 1Thermo Switch #2
P
Receiver
Dryer
2
4
3
1Thermo AmpM
1
2 Cooling
Fa nRH
1
2 Cooling Fan Resister
ECM"11"1
2 C
C
Thermo Switch #1
30
BAT+
15A IGN 2
31 GND
Ef2 80A
Page 1470 of 1574
5-104 ELECTRICAL WIRING DIAGRAMS
2) GASOLINE - MSE
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Engine Enginex - Main Main - Air Con MainEngine
C101 (21Pin, Colorless)C103 (21Pin, White)C109 (16Pin, Black) C212 (17Pin, White) S204 (Black) G103
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Behind The Glove BoxUpper Right The Audio Behind The Right Head Lamp
COOLING
RESISTER
12
C109
W/H ENGINEC212
W/H MAIN
12345 678910
11 12 13 14 15 16 17
COOLING FAN (LH)
12
12121234
A1 A9 A8A16
B1B11 B20
B101234 567
8 9 10 11 12 13 14 15 16
COOLING
FAN (RH) RECEIVER
DRYER
SWITCH THERMO
AMP FATC
A/C CONTROL
PANEL
1
13
37
36
60
23456789101112
61
73
97
96
120
62 63 64 65 66 67 68 69 70 71 72
ECM (MSE)C103
W/H MAIN
Cooling Fan Relay #2
Cooling Fan Relay #130 86
87
BGBG
BG
85
Ef5
30A
G103 B
L
L LW LWLWLW
LW
L
L R
M
1
1
2 R
RL
Y
R
B
Cooling
FanLH
30 86
87 85 1
5
S204
F19
10A
A/C
Relay30
86
87
85Cooling Fan
Motor Relay
30
86
87 85
11C101
1
C103
Ef8
60A
Ef17
10A
C1013 C101
8
C212
11 C109
7C109
16
A16
FAT C
SATC/ MTC
A/C Switch
A/C Switch BG
BY BY LW
BW
BW
BrR SIG
BrR
A/C
Compressor
LB
2 1
P
Receiver
Dryer
35
44 27
ECM
34 1Thermo
Amp
M
1
2 Cooling
Fa nRH
1
2 Cooling Fan Resister
30
BAT+
15A IGN 2
31 GND
F24
10AEf2 80A
1
2
Page 1472 of 1574
5-106 ELECTRICAL WIRING DIAGRAMS
3) DIESEL
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Air Con Main Engine Engine
C101 (21Pin, Colorless)C212 (17Pin, White)S204 (Black) G102 G103
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Behind The Glove Box Upper Right The Audio Beside The Start MotorBehind The Right Head Lamp
C212
W/H MAIN
12345 678910
11 12 13 14 15 16 17
COOLING FAN
(DSL, NA)
121212
123
A1 A9 A8A16
B1B11 B20
B101234 567
8 9 10 11 12 13 14 15 16
COOLING
FAN
(DSL, LA) RECEIVER
DRYER
THERMO AMP FATC
A/C CONTROL
PANEL
12
THERMO
SWITCH
Cooling Fan Relay #2
Cooling Fan
Relay #130 86
87
BGBG BY
YY
BG
85
E
f5
30A
G103 G102 B
L
LL W L WLW
LB
BY LW
LR
M
1
1
2
R B
B
Cooling
Fa n
30 86
87 85 1
5
S204
F19
10A
A/C
Relay30 86
87 85A/C
Compressor Relay30 86
87 85
11C101
E
f8
10A
Ef17
10A
C1013
C1018
C212
11 C109
7
A16
FAT C
SATC/ MTC
A/C Switch A/C Switch 1
2 CThermo Switch
A/CCompressor
TCM
"A4"
C10114 BG
LW
BW BW
BrR
BrR
2
23
1
1
P
Receiver
Dryer
Thermo Amp
30 BAT+
15A IGN 2
31 GND
Ef2 80A
Page 1486 of 1574
5-120 ELECTRICAL WIRING DIAGRAMS
2) SENSOR (AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT
C109
W/H ENGINE
Main - Engine Engine - Main Main - Air Con MainMain Main
C101 (21Pin, Colorless) C109 (16Pin, Black) C212 (17Pin, White) S202 (Gray) S203 (Gray) G203
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Behind The Glove BoxBehind The Cluster Upper Right The Audio Upper The ECM
C212
W/H MAIN
12345 678910
11 12 13 14 15 16 17
INCAR
SENSOR
1212
AMBIENT SENSOR
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
AUTO AMP
A1
A9 A8A16
B1 B7
B6B12121 3456
212
SUN SENSOR AIR MIX DOOR
MOTORWATER SENSOR
1
8
S202
F17
10A
A6
G203
A9 A8
A1
BY BY
BY GB
FAT C RY RY
10
C212 1
6
S203
E
f10
10A
A7 GW
GW
7
C212
A16 BG
7 1
2
12
C212
4
C101
3
C101
A14 WL
GY GR G GL BL
WR BL
5V
B+
GND GND 5V5V
SIG
4
C212
A13WR3
C212 C212
Cooling Fan
Relay
#1, #2 "85"
Sun Sensor
SIG
A12
A11
B7
A3 B6
SIG
B10 LW
BL
1
2
5V
SIG
B8 RB
BL
BY
W
BL
1
2
5V
SIG
B9 B
B
Incar
Sensor
1
C109
6
Water Sensor
AmbientSensor
5C109
2
C212
12
C2126
C21215 C212
Blower
Circuit
B Air Mix Door Motor264 13
M
30
BAT+
58 ILL
31 GND